Resin composition and molded article thereof

Abstract

To provide a resin composition having excellent properties such as transparency, heat resistance, impact resistance, weather resistance, surface hardness and wear resistance, and a molding thereof.SOLUTION: A resin composition contains (A) a polycarbonate resin, (B) an acrylic resin and (C) a slide modifier, with a coefficient of kinetic friction of 0.05-0.30.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a resin composition containing a polycarbonate resin, an acrylic resin, and a sliding modifier, and to a molded article thereof. [Background technology]

[0002] Conventionally, methacrylic resins and polycarbonate resins (hereinafter sometimes referred to as PC) have been known as transparent resins, and they are used in a wide range of fields, such as electrical and electronic components, optical components, automotive components, and mechanical components, in the form of molded products, films, and sheets.

[0003] Methacrylic acid resins such as polymethyl methacrylate (hereinafter sometimes referred to as PMMA) have high transparency and a high surface hardness (pencil hardness H to 3H), and are widely used as optical materials for lenses, optical fibers, etc. However, their low glass transition temperature of around 100°C and poor heat resistance limit their use in fields requiring heat resistance. Another problem is their low impact resistance.

[0004] Polycarbonate resins made from bisphenol A are widely used in vehicles and building materials due to their excellent heat resistance, impact resistance, flame retardancy, and transparency. Among these applications, high weather resistance is required, especially for outdoor use. However, the weather resistance of polycarbonate resins is generally inferior to that of other transparent materials such as acrylic resins, and they tend to yellow and devitrify when exposed to the outdoors. Furthermore, their surfaces are very soft (pencil hardness 4B to 2B), making them susceptible to scratches.

[0005] In recent years, polycarbonate resins using ether group-containing diols, such as isosorbide, a plant-derived raw material, have been developed with the aim of reducing environmental impact (Patent Document 1). Polycarbonate resins using isosorbide have excellent heat resistance, weather resistance, and impact resistance, and therefore their application to automobile interior and exterior parts, etc., is being considered (Patent Document 2). In particular, for automobile interior and exterior applications, improved abrasion resistance is required to prevent scratches that occur during use. Therefore, compositions using silicone compounds or special fatty acid amides have been reported with the aim of improving the abrasion resistance of polycarbonates made from isosorbide (Patent Documents 3 and 4). However, according to the inventors' investigations, these compositions have been found to have problems such as insufficient improvement in abrasion resistance tests and low surface hardness.

[0006] It is also known that blends of PC and PMMA are essentially incompatible and produce opaque materials. For example, Patent Document 5 shows that blends of PC and PMMA are opaque and do not exhibit the physical properties of both polymers.

[0007] To solve these problems, a resin composition using a polycarbonate with a special structure and an acrylic resin has been reported (Patent Document 6), which achieves both the excellent properties of PC and PMMA. However, according to the inventors' investigations, it was found that the resin composition described in Patent Document 6 exhibits high surface hardness but has poor sliding properties. Therefore, no composition has been reported to date that has an excellent balance of transparency, heat resistance, impact resistance, weather resistance, surface hardness, and abrasion resistance. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] International Publication No. 2004 / 111106 [Patent Document 2] Japanese Patent Application Laid-Open No. 2013-209585 [Patent Document 3] Japanese Patent Application Laid-Open No. 2017-8140 [Patent Document 4] Japanese Patent Application Publication No. 2019-131661 [Patent Document 5] U.S. Patent No. 4,319,003 [Patent Document 6] Japanese Patent Application Laid-Open No. 2015-232091 Summary of the Invention [Problem to be solved by the invention]

[0009] An object of the present invention is to provide a resin composition having excellent properties such as transparency, heat resistance, impact resistance, weather resistance, surface hardness and abrasion resistance, and a molded article thereof. [Means for solving the problem]

[0010] As a result of extensive research, the present inventors have discovered that adding a sliding modifier to a composition of polycarbonate resin and acrylic resin results in a resin composition and a molded article having excellent properties such as transparency, heat resistance, impact resistance, weather resistance, surface hardness, and abrasion resistance, and have completed the present invention. That is, according to the present invention, the object of the invention is achieved by the following items 1 to 12.

[0011] 1. A resin composition comprising (A) a polycarbonate resin, (B) an acrylic resin, and (C) a sliding modifier, and having a dynamic friction coefficient of 0.05 to 0.30. 2. The resin composition according to item 1 above, wherein the polycarbonate resin (A) contains 5 to 85 mol % of repeating units (a-1) represented by the following formula (1) based on all repeating units:

[0012] [ka]

[0013] (In the formula, W represents an alkylene group having 1 to 20 carbon atoms or a cycloalkylene group having 6 to 20 carbon atoms, R1 represents a branched or linear alkyl group having 1 to 20 carbon atoms or a cycloalkyl group having 6 to 20 carbon atoms which may have a substituent, and m represents an integer of 0 to 10.)

[0014] 3. The resin composition according to item 1 or 2 above, wherein the polycarbonate resin (A) contains 15 to 95 mol % of repeating units (a-2) represented by the following formula (2) based on all repeating units:

[0015] [ka]

[0016] 4. The resin composition according to any one of items 1 to 3 above, wherein (B) the acrylic resin contains 10 to 100 mol % of a repeating unit (b) represented by the following formula (3):

[0017] [ka]

[0018] (In the formula, R2 represents a hydrogen atom or a methyl group, and R3 represents a branched or linear alkyl group having 1 to 20 carbon atoms or a cycloalkyl group having 6 to 20 carbon atoms which may have a substituent.)

[0019] 5. The resin composition according to item 4 above, wherein the repeating unit (b) is a unit (b) derived from methyl methacrylate and / or methyl acrylate. 6. The resin composition according to any one of items 1 to 5 above, wherein the weight ratio of (A) polycarbonate resin to (B) acrylic resin is 1:99 to 99:1. 7. The resin composition according to any one of items 1 to 6 above, wherein the content of the (C) sliding modifier is 0.1 to 20 parts by weight per 100 parts by weight of the total of the polycarbonate resin and the acrylic resin. 8. The resin composition according to any one of items 1 to 7 above, wherein the sliding modifier (C) is a fatty acid amide-based sliding modifier. 9. The resin composition according to any one of items 1 to 8 above, which has a pencil hardness of H or more as measured in accordance with JIS K5400. 10. The resin composition according to any one of items 1 to 9 above, wherein a molded article having a thickness of 2 mm obtained by molding the resin composition has a haze of 10% or less. 11. A molded article obtained by molding the resin composition according to any one of items 1 to 10 above. 12. A film or sheet formed from the resin composition according to any one of items 1 to 10 above. [Effects of the Invention]

[0020] The present invention provides a resin composition having excellent properties such as transparency, heat resistance, impact resistance, weather resistance, surface hardness, and abrasion resistance by incorporating a sliding modifier into a composition of polycarbonate resin and acrylic resin, and therefore has exceptional industrial effects. DETAILED DESCRIPTION OF THE INVENTION

[0021] The present invention will be described in detail below.

[0022] [(A) Polycarbonate resin] The structure of the polycarbonate resin used in the resin composition of the present invention is not particularly limited as long as it has a carbonate bond. Among the polycarbonate resins, polycarbonate resins containing a repeating unit (a-1) represented by the following formula (1) and / or a unit (a-2) represented by the following formula (2) are preferred.

[0023] [ka]

[0024] (In the formula, W represents an alkylene group having 1 to 20 carbon atoms or a cycloalkylene group having 6 to 20 carbon atoms, R1 represents a branched or linear alkyl group having 1 to 20 carbon atoms or a cycloalkyl group having 6 to 20 carbon atoms which may have a substituent, and m represents an integer of 0 to 10.)

[0025] [ka]

[0026] The unit (a-1) represented by the formula (1) is derived from a diol having a spiro ring structure. Examples of the diol compound having a spiro ring structure include alicyclic diol compounds such as 3,9-bis(2-hydroxyethyl)-2,4,8,10-tetraoxaspiro(5.5)undecane, 3,9-bis(2-hydroxy-1,1-dimethylethyl)-2,4,8,10-tetraoxaspiro(5.5)undecane, 3,9-bis(2-hydroxy-1,1-diethylethyl)-2,4,8,10-tetraoxaspiro(5.5)undecane, and 3,9-bis(2-hydroxy-1,1-dipropylethyl)-2,4,8,10-tetraoxaspiro(5.5)undecane. Preferably, 3,9-bis(2-hydroxy-1,1-dimethylethyl)-2,4,8,10-tetraoxaspiro(5.5)undecane is used.

[0027] The polycarbonate resin used in the resin composition of the present invention preferably contains 5 to 85 mol %, more preferably 10 to 80 mol %, even more preferably 15 to 75 mol %, and particularly preferably 20 to 70 mol % of the repeating units of the polycarbonate resin represented by the above formula (1) in all repeating units. When the proportion of the unit (a-1) is within the above range, the resin composition does not become cloudy due to phase separation during extrusion or molding of the resin composition with the acrylic resin, and the polymerization of the polycarbonate resin is easy without crystallization during polymerization, which is preferable. The unit (a-2) represented by the above formula (2) is derived from an aliphatic diol having an ether group.

[0028] Examples of the unit (a-2) include units (a-2-1), (a-2-2) and (a-2-3) represented by the following formulae, which are stereoisomers.

[0029] [ka]

[0030] These are ether diols derived from carbohydrates and are obtained from natural biomass, making them one of the renewable resources. The repeating units (a-2-1), (a-2-2), and (a-2-3) are called isosorbide, isomannide, and isoidide, respectively. Isosorbide is obtained by hydrogenating D-glucose obtained from starch and then dehydrating it. Other ether diols can be obtained by similar reactions, except for the starting material.

[0031] Among isosorbide, isomannide and isoidide, the repeating unit derived from isosorbide (1,4;3,6-dianhydro-D-sorbitol) is particularly preferred because of its ease of production and excellent heat resistance.

[0032] The repeating unit (a-2) preferably accounts for 15 to 95 mol %, more preferably 20 to 90 mol %, even more preferably 25 to 85 mol %, and particularly preferably 30 to 80 mol % of all repeating units. When the proportion of the unit (a-2) is within the above range, an excellent balance of impact resistance, heat resistance, surface hardness, and weather resistance is achieved, which is preferred.

[0033] In the polycarbonate resin used in the resin composition of the present invention, examples of the repeating unit (a-3) constituting the copolymerization structural unit other than the unit (a-1) and the unit (a-2) include repeating units (a-3) derived from various diol compounds and dihydroxy compounds.

[0034] Aliphatic diol compounds include 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,8-octanediol, 1,9-nonanediol, 1,10-decanediol, 1,12-dodecanediol, 2-methyl-1,3-propanediol, neopentyl glycol, 3-methyl-1,5-pentanediol, 2-n-butyl-2-ethyl-1,3-propanediol, and 2,2-diethyl-1,3-propanediol. Examples include 2,4-diethyl-1,5-pentanediol, 1,2-hexane glycol, 1,2-octyl glycol, 2-ethyl-1,3-hexanediol, 2,3-diisobutyl-1,3-propanediol, 2,2-diisoamyl-1,3-propanediol, and 2-methyl-2-propyl-1,3-propanediol, and 1,8-octanediol, 1,9-nonanediol, 1,10-decanediol, and 1,12-dodecanediol are preferably used.

[0035] Examples of the alicyclic diol compound include cyclohexanediols such as 1,2-cyclohexanediol, 1,3-cyclohexanediol, 1,4-cyclohexanediol, and 2-methyl-1,4-cyclohexanediol; cyclohexanedimethanols such as 1,2-cyclohexanedimethanol, 1,3-cyclohexanedimethanol, and 1,4-cyclohexanedimethanol; norbornanedimethanols such as 2,3-norbornanedimethanol and 2,5-norbornanedimethanol; tricyclodecane dimethanol, pentacyclopentadecanedimethanol, 1,3-adamantanediol, 2,2-adamantanediol, decalindimethanol, and 2,2,4,4-tetramethyl-1,3-cyclobutanediol, and preferably use is made of cyclohexanedimethanols and 4,4-tetramethyl-1,3-cyclobutanediol.

[0036] Examples of aromatic dihydroxy compounds include α,α'-bis(4-hydroxyphenyl)-m-diisopropylbenzene (bisphenol M), 9,9-bis(4-hydroxy-3-methylphenyl)fluorene, 1,1-bis(4-hydroxyphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, 4,4'-dihydroxy-3,3'-dimethyldiphenyl sulfide, bisphenol A, 2,2-bis(4-hydroxy-3-methylphenyl)propane (bisphenol C), 2,2-bis(4-hydroxyphenyl)-1,1,1,3,3,3-hexafluoropropane (bisphenol AF), and 1,1-bis(4-hydroxyphenyl)decane, with 9,9-bis(4-hydroxy-3-methylphenyl)fluorene and bisphenol A being preferred.

[0037] The repeating unit (a-3) constituting the copolymerization structural units other than these units (a-1) and units (a-2) preferably accounts for 30 mol % or less of all repeating units, more preferably 25 mol % or less, even more preferably 20 mol % or less, particularly preferably 15 mol % or less, and most preferably 10 mol % or less.

[0038] (Manufacturing method of polycarbonate resin) Polycarbonate resins are produced by known reaction means for producing ordinary polycarbonate resins, for example, by reacting a diol component with a carbonate precursor such as a carbonic acid diester. The basic means for these production methods will now be briefly described.

[0039] The transesterification reaction using a carbonate diester as a carbonate precursor is carried out by stirring a predetermined ratio of diol components with the carbonate diester under heating in an inert gas atmosphere, and distilling off the resulting alcohol or phenol. The reaction temperature varies depending on the boiling point of the resulting alcohol or phenol, but is typically in the range of 120 to 300°C. The reaction is completed by reducing the pressure from the beginning of the reaction to distill off the resulting alcohol or phenol. If necessary, a terminal capping agent, antioxidant, etc. may also be added.

[0040] The carbonic acid diester used in the transesterification reaction includes esters of an aryl group or an aralkyl group having 6 to 12 carbon atoms, which may be substituted. Specific examples include diphenyl carbonate, ditolyl carbonate, bis(chlorophenyl)carbonate, and m-cresyl carbonate. Of these, diphenyl carbonate is particularly preferred. The amount of diphenyl carbonate used is preferably 0.97 to 1.10 mol, more preferably 1.00 to 1.06 mol, per mol of the total amount of dihydroxy compounds.

[0041] In the melt polymerization method, a polymerization catalyst can be used to increase the polymerization rate. Examples of such a polymerization catalyst include alkali metal compounds, alkaline earth metal compounds, nitrogen-containing compounds, and metal compounds.

[0042] As such compounds, organic acid salts, inorganic salts, oxides, hydroxides, hydrides, alkoxides, quaternary ammonium hydroxides, etc. of alkali metals or alkaline earth metals are preferably used, and these compounds can be used alone or in combination.

[0043] Examples of alkali metal compounds include sodium hydroxide, potassium hydroxide, cesium hydroxide, lithium hydroxide, sodium bicarbonate, sodium carbonate, potassium carbonate, cesium carbonate, lithium carbonate, sodium acetate, potassium acetate, cesium acetate, lithium acetate, sodium stearate, potassium stearate, cesium stearate, lithium stearate, sodium borohydride, sodium benzoate, potassium benzoate, cesium benzoate, lithium benzoate, disodium hydrogen phosphate, dipotassium hydrogen phosphate, dilithium hydrogen phosphate, disodium phenylphosphate, disodium salt, dipotassium salt, dicesium salt, dilithium salt of bisphenol A, sodium salt, potassium salt, cesium salt, and lithium salt of phenol.

[0044] Examples of alkaline earth metal compounds include magnesium hydroxide, calcium hydroxide, strontium hydroxide, barium hydroxide, magnesium carbonate, calcium carbonate, strontium carbonate, barium carbonate, magnesium diacetate, calcium diacetate, strontium diacetate, barium diacetate, and barium stearate.

[0045] Examples of nitrogen-containing compounds include quaternary ammonium hydroxides having alkyl or aryl groups, such as tetramethylammonium hydroxide, tetraethylammonium hydroxide, tetrapropylammonium hydroxide, tetrabutylammonium hydroxide, and trimethylbenzylammonium hydroxide. Other examples include tertiary amines, such as triethylamine, dimethylbenzylamine, and triphenylamine, and imidazoles, such as 2-methylimidazole, 2-phenylimidazole, and benzimidazole. Other examples include bases or basic salts, such as ammonia, tetramethylammonium borohydride, tetrabutylammonium borohydride, tetrabutylammonium tetraphenylborate, and tetraphenylammonium tetraphenylborate.

[0046] Examples of metal compounds include zinc aluminum compounds, germanium compounds, organotin compounds, antimony compounds, manganese compounds, titanium compounds, zirconium compounds, etc. These compounds may be used alone or in combination of two or more.

[0047] The amount of the polymerization catalyst used is preferably 1×10 -9 ~1×10 -2 equivalent, preferably 1 x 10 -8 ~1×10 -5 equivalent, more preferably 1 x 10 -7 ~1×10 -3 It is selected within the range of equivalents.

[0048] A catalyst deactivator can also be added in the latter stage of the reaction. Known catalyst deactivators are effectively used as the catalyst deactivator, but among these, ammonium salts and phosphonium salts of sulfonic acid are preferred. Salts of dodecylbenzenesulfonic acid, such as tetrabutylphosphonium dodecylbenzenesulfonate, and salts of paratoluenesulfonic acid, such as tetrabutylammonium paratoluenesulfonate, are more preferred.

[0049] Preferred examples of sulfonic acid esters include methyl benzenesulfonate, ethyl benzenesulfonate, butyl benzenesulfonate, octyl benzenesulfonate, phenyl benzenesulfonate, methyl paratoluenesulfonate, ethyl paratoluenesulfonate, butyl paratoluenesulfonate, octyl paratoluenesulfonate, and phenyl paratoluenesulfonate. Of these, tetrabutylphosphonium dodecylbenzenesulfonate is most preferably used.

[0050] When at least one polymerization catalyst selected from alkali metal compounds and / or alkaline earth metal compounds is used, the amount of these catalyst deactivators used is preferably 0.5 to 50 mol, more preferably 0.5 to 10 mol, and even more preferably 0.8 to 5 mol, per mol of the catalyst.

[0051] (Specific viscosity:η SP ) The specific viscosity (η SP ) is preferably 0.2 to 1.5, more preferably 0.25 to 1.0, still more preferably 0.3 to 0.7, and particularly preferably 0.35 to 0.5. When the specific viscosity is within the above range, the strength and molding processability of the molded article will be good.

[0052] The specific viscosity referred to in the present invention is determined by using an Ostwald viscometer to measure a solution of 0.7 g of polycarbonate resin dissolved in 100 ml of methylene chloride at 20°C. Specific viscosity (η SP )=(t-t0) / t0 [t0 is the number of seconds that methylene chloride falls, and t is the number of seconds that the sample solution falls] The specific viscosity can be measured, for example, as follows: First, polycarbonate resin is dissolved in methylene chloride in an amount 20 to 30 times its weight, and the soluble matter is collected by filtration through Celite. After removing the solution, the mixture is thoroughly dried to obtain a solid soluble in methylene chloride. 0.7 g of this solid is dissolved in 100 ml of methylene chloride, and the specific viscosity at 20°C is determined using an Ostwald viscometer.

[0053] [(B) Acrylic resin] The structure of the acrylic resin used in the resin composition of the present invention is not particularly limited. Among the acrylic resins, acrylic resins containing a repeating unit (b) represented by the following formula (3) are preferred.

[0054] [ka]

[0055] (In the formula, R2 represents a hydrogen atom or a methyl group, and R3 represents a branched or linear alkyl group having 1 to 20 carbon atoms or a cycloalkyl group having 6 to 20 carbon atoms which may have a substituent.)

[0056] Examples of the monomer that derives the unit (b) represented by the above formula (3) include compounds such as methyl methacrylate, methyl acrylate, benzyl (meth)acrylate, n-butyl (meth)acrylate, i-butyl (meth)acrylate, t-butyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, cyclohexyl (meth)acrylate, norbornyl (meth)acrylate, dicyclopentenyl (meth)acrylate, dicyclopentanyl (meth)acrylate, dicyclopentenyloxyethyl (meth)acrylate, cyclopentyl methacrylate, cyclopentyl acrylate, cyclohexyl methacrylate, cyclohexyl acrylate, cycloheptyl methacrylate, cycloheptyl acrylate, cyclooctyl methacrylate, cyclooctyl acrylate, cyclododecyl methacrylate, and cyclododecyl acrylate.

[0057] Other monomers that can be used include, for example, methacrylic acid, methyl methacrylate, acrylic acid, lauryl (meth)acrylate, tridecyl (meth)acrylate, stearyl (meth)acrylate, glycidyl (meth)acrylate, hydroxypropyl (meth)acrylate, 2-methoxyethyl (meth)acrylate, 2-ethoxyethyl (meth)acrylate, isobornyl (meth)acrylate, tetrahydrofurfuryl (meth)acrylate, 2-hydroxyethyl (meth)acrylate, 2-(meth)acroyloxyethyl succinate, 2-(meth)acroyloxyethyl maleate, 2-(meth)acroyloxyethyl phthalate, 2-(meth)acryloyloxyethyl hexahydrophthalate, pentamethylpiperidyl (meth)acrylate, tetramethylpiperidyl (meth)acrylate, dimethylaminoethyl (meth)acrylate, and diethylaminoethyl (meth)acrylate.

[0058] These may be polymerized singly or in combination of two or more. Among these, it is preferable to use methyl methacrylate and / or methyl acrylate as the monomer from which the unit (b) is derived, and it is particularly preferable to use methyl methacrylate.

[0059] The acrylic resin of the present invention preferably contains 10 to 100 mol %, more preferably 20 to 99 mol %, even more preferably 30 to 95 mol %, and particularly preferably 50 to 90 mol % of repeating unit (b). When the repeating unit (b) is within the above range, the resin has excellent thermal decomposition resistance and is less likely to develop molding defects such as silver during molding. It also has excellent heat resistance and is less likely to have a lower heat distortion temperature. Furthermore, other monomers that can be polymerized with these acrylic monomers, such as polyolefin monomers and vinyl monomers, may be used in combination.

[0060] The molecular weight of the acrylic resin is not particularly limited, but as long as the weight-average molecular weight is in the range of 30,000 or more and 300,000 or less, a resin composition can be provided that does not cause poor appearance such as uneven flow during molding and has excellent mechanical properties and heat resistance.

[0061] The acrylic resin used in the resin composition of the present invention preferably has a specific viscosity in the range of 0.12 to 0.55. Within this range, the molded product will not become brittle, and the melt viscosity of the resin will be appropriate, resulting in excellent moldability.

[0062] The glass transition temperature (Tg) of the acrylic resin used in the present invention is preferably 90 to 150° C., more preferably 95 to 145° C., and even more preferably 100 to 140° C. If the Tg is within the above range, the heat resistance and moldability are good, which is preferable.

[0063] The glass transition temperature (Tg) is measured using a 2910 DSC manufactured by TA Instruments Japan Co., Ltd. at a heating rate of 20°C / min.

[0064] The acrylic resin of the present invention is not particularly limited, but is preferably an acrylic resin having a melt flow rate of 0.5 to 30 g / 10 min measured in accordance with JIS K7210 at 230°C under a load of 3.8 kg. The melt flow rate is more preferably 0.7 to 27 g / 10 min, and even more preferably 1.0 to 25 g / 10 min. Acrylic resins having a melt flow rate within this range have good moldability.

[0065] [(C) Sliding modifier] The sliding modifier preferably used in the resin composition of the present invention is not particularly limited as long as it has a sliding property improving effect, but fatty acid amides are preferred from the viewpoint of compatibility. (fatty acid amides) From the viewpoint of improving wear resistance, the fatty acid amide preferably used as a sliding modifier has a terminal alkyl group having preferably 10 or more carbon atoms, more preferably 12 or more carbon atoms, even more preferably 14 or more carbon atoms, and most preferably 16 or more carbon atoms. On the other hand, from the viewpoint of improving the appearance of molded articles, the terminal alkyl group of the fatty acid amide has preferably 30 or less carbon atoms, more preferably 25 or less carbon atoms, even more preferably 20 or less carbon atoms, and most preferably 18 or less carbon atoms.

[0066] Specific examples of fatty acid amides include stearic acid amide (e.g., Amide AP-1 manufactured by Mitsubishi Chemical Corporation), methylene bisstearic acid amide (e.g., Bisamide LA manufactured by Mitsubishi Chemical Corporation), ethylene bishydroxystearic acid amide (e.g., Slipax H manufactured by Nippon Kasei Chemical Co., Ltd.), hexamethylene bishydroxystearic acid amide (e.g., Slipax ZHH manufactured by Nippon Kasei Chemical Co., Ltd.), and m-xylylene bishydroxystearic acid amide (e.g., Slipax PXH manufactured by Nippon Kasei Chemical Co., Ltd.).

[0067] From the viewpoint of thermal stability, fatty acid amides having no polar group are preferred, and in particular, stearic acid amide (e.g., Amide AP-1 manufactured by Mitsubishi Chemical Corporation) and methylene bisstearic acid amide (e.g., Bisamide LA manufactured by Mitsubishi Chemical Corporation) are preferably used.

[0068] [Method of producing resin composition] The resin composition of the present invention is preferably prepared by blending (A) polycarbonate resin, (B) acrylic resin, and (C) sliding modifier in a molten state. As a method for blending in a molten state, an extruder is generally used, and the molten resin is kneaded and pelletized at a temperature of 200 to 320°C, preferably 220 to 300°C, and more preferably 230 to 290°C. This results in pellets of a resin composition in which both resins are uniformly blended. The configuration of the extruder, the screw configuration, etc. are not particularly limited. If the molten resin temperature in the extruder exceeds 320°C, the resin may become discolored or undergo thermal decomposition. On the other hand, if the resin temperature is below 200°C, the resin viscosity may be too high, causing an overload on the extruder.

[0069] [Weight ratio] The weight ratio of (A) polycarbonate resin to (B) acrylic resin is preferably in the range of 1:99 to 99:1, and can be arbitrarily mixed within this range. It is more preferably in the range of 10:90 to 98:2, even more preferably in the range of 20:80 to 97:3, particularly preferably in the range of 30:70 to 96:4, and most preferably in the range of 40:60 to 95:5. By adjusting the ratio within the above range, a resin composition with excellent heat resistance and impact resistance can be obtained.

[0070] The sliding modifier (C) is preferably blended in an amount of 0.1 to 20 parts by weight per 100 parts by weight of the total of the polycarbonate resin and the acrylic resin, more preferably 0.5 to 10 parts by weight, and even more preferably 1 to 5 parts by weight. When the content of the sliding modifier is within the above range, wear resistance is improved, heat resistance is maintained, and it is preferable from the viewpoint of suppressing haze due to gas generation.

[0071] [Additives] The resin composition used in the present invention may contain additives such as a heat stabilizer, a plasticizer, a light stabilizer, a polymerized metal deactivator, a flame retardant, a lubricant, an antistatic agent, a surfactant, an antibacterial agent, an ultraviolet absorber, a mold release agent, and a colorant, depending on the intended use and as needed.

[0072] (heat stabilizer) The resin composition used in the present invention preferably contains a heat stabilizer, in particular, to suppress a decrease in molecular weight and deterioration in color during extrusion and molding. Examples of heat stabilizers include phosphorus-based heat stabilizers, phenol-based heat stabilizers, and sulfur-based heat stabilizers, and these can be used alone or in combination of two or more. It is preferable to incorporate a phosphite compound as the phosphorus-based stabilizer. Examples of phosphite compounds include pentaerythritol-type phosphite compounds, phosphite compounds that react with dihydric phenols to form a cyclic structure, and phosphite compounds with other structures.

[0073] Specific examples of the pentaerythritol phosphite compounds include distearyl pentaerythritol diphosphite, bis(2,4-di-tert-butylphenyl)pentaerythritol diphosphite, bis(2,6-di-tert-butyl-4-methylphenyl)pentaerythritol diphosphite, bis(2,6-di-tert-butyl-4-ethylphenyl)pentaerythritol diphosphite, phenylbisphenol A pentaerythritol diphosphite, bis(nonylphenyl)pentaerythritol diphosphite, and dicyclohexyl pentaerythritol diphosphite. Of these, distearyl pentaerythritol diphosphite and bis(2,4-di-tert-butylphenyl)pentaerythritol diphosphite are preferred.

[0074] Examples of the phosphite compounds having a cyclic structure that react with the above dihydric phenols include 2,2'-methylenebis(4,6-di-tert-butylphenyl)(2,4-di-tert-butylphenyl)phosphite, 2,2'-methylenebis(4,6-di-tert-butylphenyl)(2-tert-butyl-4-methylphenyl)phosphite, 2,2'-methylenebis(4-methyl-6-tert-butylphenyl)(2-tert-butyl-4-methylphenyl)phosphite, phosphite, 2,2'-ethylidenebis(4-methyl-6-tert-butylphenyl)(2-tert-butyl-4-methylphenyl)phosphite, 2,2'-methylene-bis-(4,6-di-t-butylphenyl)octylphosphite, 6-tert-butyl-4-[3-[(2,4,8,10)-tetra-tert-butyldibenzo[d,f][1,3,2]dioxaphosphepin-6-yl)oxy]propyl]-2-methylphenol, and the like.

[0075] Examples of phosphite compounds having the above other structures include triphenyl phosphite, tris(nonylphenyl)phosphite, tridecyl phosphite, trioctyl phosphite, trioctadecyl phosphite, didecyl monophenyl phosphite, dioctyl monophenyl phosphite, diisopropyl monophenyl phosphite, monobutyl diphenyl phosphite, monodecyl diphenyl phosphite, monooctyl diphenyl phosphite, 2,2-methylenebis(4,6-di-tert-butylphenyl)octyl phosphite, tris(diethylphenyl)phosphite, tris(di-isopropylphenyl)phosphite, tris(di-n-butylphenyl)phosphite, tris(2,4-di-tert-butylphenyl)phosphite, and tris(2,6-di-tert-butylphenyl)phosphite.

[0076] In addition to the various phosphite compounds, examples of the compounds include phosphate compounds, phosphonite compounds, and phosphonate compounds.

[0077] Examples of the phosphate compound include tributyl phosphate, trimethyl phosphate, tricresyl phosphate, triphenyl phosphate, trichlorophenyl phosphate, triethyl phosphate, diphenyl cresyl phosphate, diphenyl monoorthoxenyl phosphate, tributoxyethyl phosphate, dibutyl phosphate, dioctyl phosphate, and diisopropyl phosphate, and preferred are triphenyl phosphate and trimethyl phosphate.

[0078] Examples of phosphonite compounds include tetrakis(2,4-di-tert-butylphenyl)-4,4'-biphenylene diphosphonite, tetrakis(2,4-di-tert-butylphenyl)-4,3'-biphenylene diphosphonite, tetrakis(2,4-di-tert-butylphenyl)-3,3'-biphenylene diphosphonite, tetrakis(2,6-di-tert-butylphenyl)-4,4'-biphenylene diphosphonite, tetrakis(2,6-di-tert-butylphenyl)-4,3'-biphenylene diphosphonite, tetrakis(2,6-di-tert-butylphenyl)-3,3'-biphenylene diphosphonite, bis(2,4-di-tert-butylphenyl)-4-phenyl ... Examples include (2,4-di-tert-butylphenyl)-3-phenyl-phenylphosphonite, bis(2,6-di-n-butylphenyl)-3-phenyl-phenylphosphonite, bis(2,6-di-tert-butylphenyl)-4-phenyl-phenylphosphonite, and bis(2,6-di-tert-butylphenyl)-3-phenyl-phenylphosphonite. Tetrakis(di-tert-butylphenyl)-biphenylene diphosphonite and bis(di-tert-butylphenyl)-phenyl-phenylphosphonite are preferred, with tetrakis(2,4-di-tert-butylphenyl)-biphenylene diphosphonite and bis(2,4-di-tert-butylphenyl)-phenyl-phenylphosphonite being more preferred. Such phosphonite compounds can be used in combination with, and are preferred for, the above-mentioned phosphite compounds having an aryl group substituted with two or more alkyl groups.

[0079] Examples of the phosphonate compound include dimethyl benzenephosphonate, diethyl benzenephosphonate, and dipropyl benzenephosphonate.

[0080] Among the above phosphorus-based heat stabilizers, trisnonylphenyl phosphite, trimethyl phosphate, tris(2,4-di-tert-butylphenyl) phosphite, bis(2,4-di-tert-butylphenyl)pentaerythritol diphosphite, and bis(2,6-di-tert-butyl-4-methylphenyl)pentaerythritol diphosphite are preferably used.

[0081] The above phosphorus-based heat stabilizers can be used alone or in combination of two or more. The phosphorus-based heat stabilizer is preferably blended in an amount of 0.001 to 1 part by weight, more preferably 0.01 to 0.5 parts by weight, and even more preferably 0.01 to 0.3 parts by weight per 100 parts by weight of the total of the polycarbonate resin and the acrylic resin.

[0082] The resin composition used in the present invention may contain a heat stabilizer, such as a hindered phenol-based heat stabilizer or a sulfur-based heat stabilizer, in combination with a phosphorus-based heat stabilizer, in order to suppress a decrease in molecular weight or deterioration in color during extrusion and molding.

[0083] The hindered phenol-based heat stabilizer is not particularly limited as long as it has an antioxidant function, and examples thereof include n-octadecyl-3-(4'-hydroxy-3',5'-di-t-butylphenyl)propionate, tetrakis{methylene-3-(3',5'-di-t-butyl-4-hydroxyphenyl)propionate}methane, distearyl(4-hydroxy-3-methyl-5-t-butylbenzyl)malonate, triethyleneglycol-bis{3-(3-t-butyl-5-methyl-4-hydroxyphenyl)propionate}, 1,6-hexanediol-bis{3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate}, pentaerythrityl-tetrakis{3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate}, 2,2- Thiodiethylene bis{3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate}, 2,2-thiobis(4-methyl-6-t-butylphenol), 1,3,5-trimethyl-2,4,6-tris(3,5-di-t-butyl-4-hydroxybenzyl)benzene, tris(3,5-di-t-butyl-4-hydroxybenzyl)isocyanurate, 2,4-bis{(octyl thio)methyl}-o-cresol, isooctyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate, 2,5,7,8-tetramethyl-2(4',8',12'-trimethyltridecyl)chroman-6-ol, 3,3',3",5,5',5"-hexa-t-butyl-a,a',a"-(mesitylene-2,4,6-triyl)tri-p-cresol, and the like.

[0084] Among these, n-octadecyl-3-(4'-hydroxy-3',5'-di-t-butylphenyl)propionate, pentaerythrityl-tetrakis{3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate}, 3,3',3",5,5',5"-hexa-t-butyl-a,a',a'-(mesitylene-2,4,6-triyl)tri-p-cresol, 2,2-thiodiethylenebis{3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate}, and the like are preferred.

[0085] These hindered phenol-based heat stabilizers may be used alone or in combination of two or more. The hindered phenol-based heat stabilizer is preferably blended in an amount of 0.001 to 1 part by weight, more preferably 0.01 to 0.5 parts by weight, and even more preferably 0.01 to 0.3 parts by weight, per 100 parts by weight of the total of the polycarbonate resin and the acrylic resin.

[0086] Examples of sulfur-based heat stabilizers include dilauryl-3,3'-thiodipropionate, ditridecyl-3,3'-thiodipropionate, dimyristyl-3,3'-thiodipropionate, distearyl-3,3'-thiodipropionate, laurylstearyl-3,3'-thiodipropionate, pentaerythritol tetrakis(3-laurylthiopropionate), bis[2-methyl-4-(3-laurylthiopropionyloxy)-5-tert-butylphenyl]sulfide, octadecyl disulfide, mercaptobenzimidazole, 2-mercapto-6-methylbenzimidazole, and 1,1'-thiobis(2-naphthol). Of these, pentaerythritol tetrakis(3-laurylthiopropionate) is preferred.

[0087] These sulfur-based heat stabilizers may be used alone or in combination of two or more. The sulfur-based heat stabilizer is preferably blended in an amount of 0.001 to 1 part by weight, more preferably 0.01 to 0.5 parts by weight, and even more preferably 0.01 to 0.3 parts by weight, per 100 parts by weight of the total of the polycarbonate resin and the acrylic resin.

[0088] When a phosphite-based heat stabilizer, a phenol-based heat stabilizer, and a sulfur-based heat stabilizer are used in combination, the total amount of these is preferably 0.001 to 1 part by weight, more preferably 0.01 to 0.3 parts by weight, per 100 parts by weight of the polycarbonate resin and the acrylic resin combined.

[0089] (mold release agent) The resin composition used in the present invention may contain a mold release agent in order to further improve the releasability from the mold during melt molding, within the range that does not impair the object of the present invention. Examples of such release agents include higher fatty acid esters of monohydric or polyhydric alcohols, higher fatty acids, paraffin wax, beeswax, olefin-based waxes, olefin-based waxes containing carboxy groups and / or carboxylic anhydride groups, silicone oils, and organopolysiloxanes.

[0090] The higher fatty acid ester is preferably a partial or full ester of a monohydric or polyhydric alcohol having 1 to 20 carbon atoms with a saturated fatty acid having 10 to 30 carbon atoms. Examples of such partial or full esters of a monohydric or polyhydric alcohol with a saturated fatty acid include stearic acid monoglyceride, stearic acid diglyceride, stearic acid triglyceride, stearate monosorbitate, stearyl stearate, behenic acid monoglyceride, behenyl behenate, pentaerythritol monostearate, pentaerythritol tetrastearate, pentaerythritol tetrapelargonate, propylene glycol monostearate, stearyl stearate, palmityl palmitate, butyl stearate, methyl laurate, isopropyl palmitate, biphenyl biphenate, sorbitan monostearate, and 2-ethylhexyl stearate. Among these, stearic acid monoglyceride, stearic acid triglyceride, pentaerythritol tetrastearate, and behenyl behenate are preferably used.

[0091] The higher fatty acid is preferably a saturated fatty acid having 10 to 30 carbon atoms. Examples of such fatty acids include myristic acid, lauric acid, palmitic acid, stearic acid, and behenic acid.

[0092] These release agents may be used alone or in combination of two or more. The amount of such release agent to be added is preferably 0.01 to 5 parts by weight per 100 parts by weight of the total of the polycarbonate resin and the acrylic resin.

[0093] (ultraviolet absorber) The resin composition used in the present invention may contain an ultraviolet absorber, such as a benzotriazole-based ultraviolet absorber, a benzophenone-based ultraviolet absorber, a triazine-based ultraviolet absorber, a cyclic iminoester-based ultraviolet absorber, or a cyanoacrylate-based ultraviolet absorber, with benzotriazole-based ultraviolet absorbers being preferred.

[0094] Examples of the benzotriazole-based ultraviolet absorber include 2-(2'-hydroxy-5'-methylphenyl)benzotriazole, 2-(2'-hydroxy-5'-tert-butylphenyl)benzotriazole, 2-(2'-hydroxy-5'-tert-octylphenyl)benzotriazole, 2-(2'-hydroxy-3',5'-di-tert-butylphenyl)benzotriazole, 2-(2'-hydroxy-3',5'-di-tert-amylphenyl)benzotriazole, 2-(2'-hydroxy-3'-dodecyl-5'-methylphenyl)benzotriazole, 2-(2'-hydroxy-3',5'-bis(α,α'-dimethylbenzyl)phenylbenzotriazole, 2-[2'-hydroxy and benzotriazole-based ultraviolet absorbers typified by 2-(2'-hydroxy-3'-tert-butyl-5'-methylphenyl)benzotriazole, 2-(2'-hydroxy-3',5'-di-tert-butylphenyl)-5-chlorobenzotriazole, 2,2'methylenebis[4-(1,1,3,3-tetramethylbutyl)-6-(2H-benzotriazol-2-yl)phenol], and methyl-3-[3-tert-butyl-5-(2H-benzotriazol-2-yl)-4-hydroxyphenylpropionate-polyethylene glycol condensates.

[0095] The proportion of such ultraviolet absorber is preferably 0.01 to 2 parts by weight, more preferably 0.1 to 1 part by weight, and even more preferably 0.2 to 0.5 parts by weight, relative to 100 parts by weight of the total of the polycarbonate resin and the acrylic resin.

[0096] (light stabilizer) The resin composition used in the present invention may contain a light stabilizer, which has the advantages of improving weather resistance and making molded articles less susceptible to cracking.

[0097] Examples of light stabilizers include 1,2,2,6,6-pentamethyl-4-piperidyl methacrylate, didecanoic acid bis(2,2,6,6-tetramethyl-1-octyloxy-4-piperidinyl) ester, bis(1,2,2,6,6-pentamethyl-4-piperidinyl)-[[3,5-bis(1,1-dimethylethyl)-4-hydroxyphenyl]methyl]butyl malonate, 2,4-bis[N-butyl-N-(1-cyclohexyloxy-2,2,6,6-tetramethyl-4-piperidinyl]methyl]butyl malonate, Methylpiperidin-2-yl)amino]-6-(2-hydroxyethylamine)-1,3,5-triazine, Bis(1,2,2,6,6-pentamethyl-4-piperidinyl)sebacate, Methyl(1,2,2,6,6-pentamethyl-4-piperidinyl)sebacate, Bis(2,2,6,6-tetramethyl-4-piperidyl)carbonate, Bis(2,2,6,6-tetramethyl-4-piperidyl)succinate, Bis(2,2,6,6-tetramethyl-4-piperi diphenyl) sebacate, 4-benzoyloxy-2,2,6,6-tetramethylpiperidine, 4-octanoyloxy-2,2,6,6-tetramethylpiperidine, bis(2,2,6,6-tetramethyl-4-piperidyl)diphenylmethane-p,p'-dicarbamate, bis(2,2,6,6-tetramethyl-4-piperidyl)benzene-1,3-disulfonate, bis(2,2,6,6-tetramethyl-4-piperidyl)phenylphosphite, etc. Examples of suitable light stabilizers include nickel complexes such as nickel bis(octylphenyl sulfide), nickel complex-3,5-di-t-butyl-4-hydroxybenzyl phosphate monoethylate, and nickel dibutyldithiocarbamate. These light stabilizers may be used alone or in combination of two or more. The content of the light stabilizer is preferably 0.001 to 1 part by weight, more preferably 0.01 to 0.5 parts by weight, per 100 parts by weight of the total of the polycarbonate resin and the acrylic resin.

[0098] (epoxy stabilizer) In order to improve hydrolysis resistance, the resin composition used in the present invention may contain an epoxy compound within a range that does not impair the object of the present invention.

[0099] Epoxy stabilizers include epoxidized soybean oil, epoxidized linseed oil, phenyl glycidyl ether, allyl glycidyl ether, t-butylphenyl glycidyl ether, 3,4-epoxycyclohexylmethyl-3',4'-epoxycyclohexylcarboxylate, 3,4-epoxy-6-methylcyclohexylmethyl-3',4'-epoxy-6'-methylcyclohexylcarboxylate, 2,3-epoxycyclohexylmethyl-3',4'-epoxycyclohexylcarboxylate, 4-(3,4-epoxy-5-methylcyclohexyl) ... butyl-3',4'-epoxycyclohexylcarboxylate, 3,4-epoxycyclohexylethylene oxide, cyclohexylmethyl-3,4-epoxycyclohexylcarboxylate, 3,4-epoxy-6-methylcyclohexylmethyl-6'-methylcyclohexylcarboxylate, bisphenol A diglycidyl ether, tetrabromobisphenol A glycidyl ether, diglycidyl ester of phthalic acid, diglycidyl ester of hexahydrophthalic acid, bis-epoxydicyclopentadienyl ether, bis-epoxyethylene ethylene glycol, bis-epoxycyclohexyl adipate, butadiene diepoxide, tetraphenylethylene epoxide, octyl epoxythalate, epoxidized polybutadiene, 3,4-dimethyl-1,2-epoxycyclohexane, 3,5-dimethyl-1,2-epoxycyclohexane, 3-methyl-5-t-butyl-1,2-epoxycyclohexane, octadecyl-2,2-dimethyl-3,4-epoxycyclohexylcarboxylate, N-butyl-2,2-dimethyl-3,4-epoxycyclohexylcarboxylate, cyclohexyl- 2-Methyl-3,4-epoxycyclohexyl carboxylate, N-butyl-2-isopropyl-3,4-epoxy-5-methylcyclohexyl carboxylate, octadecyl-3,4-epoxycyclohexyl carboxylate, 2-ethylhexyl-3',4'-epoxycyclohexyl carboxylate, 4,6-dimethyl-2,3-epoxycyclohexyl-3',4'-epoxycyclohexyl carboxylate, 4,5-epoxytetrahydrophthalic anhydride, 3-t-butyl-4,5-epoxytetrahydrophthalic anhydride, diethyl-4,Examples include 5-epoxy-cis-1,2-cyclohexyldicarboxylate and di-n-butyl-3-t-butyl-4,5-epoxy-cis-1,2-cyclohexyldicarboxylate. Bisphenol A diglycidyl ether is preferred from the standpoint of compatibility.

[0100] Such an epoxy-based stabilizer is preferably blended in an amount of 0.0001 to 5 parts by weight, more preferably 0.001 to 1 part by weight, and even more preferably 0.005 to 0.5 parts by weight per 100 parts by weight of the total of the polycarbonate resin and the acrylic resin.

[0101] (Bluing agent) The resin composition used in the present invention can be blended with a bluing agent to counteract the yellow tint of the lens due to the polymer or ultraviolet absorber. Any bluing agent used in polycarbonate can be used without any particular problems. Anthraquinone dyes are generally preferred because they are readily available.

[0102] Specific examples of bluing agents include Solvent Violet 13 (CA No. (Color Index No.) 60725), Solvent Violet 31 (CA No. 68210), Solvent Violet 33 (CA No. 60725), Solvent Blue 94 (CA No. 61500), Solvent Violet 36 (CA No. 68210), Solvent Blue 97 (Macrolex Violet RR, manufactured by Bayer), and Solvent Blue 45 (CA No. 61110).

[0103] These bluing agents may be used alone or in combination of two or more. These bluing agents are preferably blended in a ratio of 0.1×10 to 2×10 parts by weight per 100 parts by weight of the total of the polycarbonate resin and the acrylic resin.

[0104] (Flame retardant) The resin composition used in the present invention may also contain a flame retardant. Examples of flame retardants include halogen-based flame retardants such as brominated epoxy resin, brominated polystyrene, brominated polycarbonate, brominated polyacrylate, and chlorinated polyethylene; phosphate ester-based flame retardants such as monophosphate compounds and phosphate oligomer compounds; organic phosphorus-based flame retardants other than phosphate ester-based flame retardants such as phosphinate compounds, phosphonate compounds, phosphonitrile oligomer compounds, and phosphonic acid amide compounds; organic metal salt-based flame retardants such as organic alkali (earth) metal sulfonates, metal borate-based flame retardants, and metal stannate-based flame retardants; silicone-based flame retardants, ammonium polyphosphate-based flame retardants, and triazine-based flame retardants. Additionally, flame retardant assistants (e.g., sodium antimonate, antimony trioxide, etc.) and anti-dripping agents (e.g., fibril-forming polytetrafluoroethylene) may be added and used in combination with the flame retardant.

[0105] Among the above-mentioned flame retardants, compounds that do not contain chlorine atoms or bromine atoms are more suitable as flame retardants for the molded article of the present invention, which is characterized by reduced environmental impact, because they reduce factors that make them undesirable when incinerated or thermally recycled.

[0106] When a flame retardant is added, the amount is preferably in the range of 0.05 to 50 parts by weight per 100 parts by weight of the total of the polycarbonate resin and the acrylic resin. If the amount is within this range, sufficient flame retardancy is exhibited and the molded product has excellent strength and heat resistance.

[0107] (elastic polymer) The resin composition used in the present invention can contain an elastomeric polymer as an impact modifier. Examples of the elastomeric polymer include natural rubber or a graft copolymer in which one or more monomers selected from aromatic vinyl, vinyl cyanide, acrylic ester, methacrylic ester, and vinyl compounds copolymerizable therewith are copolymerized with a rubber component having a glass transition temperature of 10°C or less. A more preferred elastomeric polymer is a core-shell graft copolymer in which one or more shells of the above monomers are graft copolymerized onto a core of a rubber component.

[0108] Also included are block copolymers of such rubber components and the above-mentioned monomers. Specific examples of such block copolymers include thermoplastic elastomers such as styrene-ethylene-propylene-styrene elastomers (hydrogenated styrene-isoprene-styrene elastomers) and hydrogenated styrene-butadiene-styrene elastomers. Furthermore, various elastic polymers known as thermoplastic elastomers, such as polyurethane elastomers, polyester elastomers, and polyetheramide elastomers, can also be used.

[0109] A core-shell type graft copolymer is more suitable as an impact improver. In the core-shell type graft copolymer, the particle size of the core is preferably 0.05 to 0.8 μm, more preferably 0.1 to 0.6 μm, and even more preferably 0.1 to 0.5 μm, in terms of weight average particle size. If the particle size is in the range of 0.05 to 0.8 μm, better impact resistance can be achieved. The elastomeric polymer preferably contains 40% or more of a rubber component, and more preferably 60% or more.

[0110] Examples of rubber components include butadiene rubber, butadiene-acrylic composite rubber, acrylic rubber, acrylic-silicone composite rubber, isobutylene-silicone composite rubber, isoprene rubber, styrene-butadiene rubber, chloroprene rubber, ethylene-propylene rubber, nitrile rubber, ethylene-acrylic rubber, silicone rubber, epichlorohydrin rubber, fluororubber, and rubbers thereof with hydrogen added to the unsaturated bonds. However, due to concerns about the generation of harmful substances during combustion, rubber components that do not contain halogen atoms are preferred in terms of environmental impact.

[0111] The glass transition temperature of the rubber component is preferably -10°C or lower, more preferably -30°C or lower, and the rubber component is particularly preferably butadiene rubber, butadiene-acrylic composite rubber, acrylic rubber, or acrylic-silicone composite rubber. Composite rubber refers to rubber obtained by copolymerizing two types of rubber components or rubber polymerized to form an IPN structure in which the components are inseparably entangled with each other.

[0112] Examples of aromatic vinyl compounds in the vinyl compounds copolymerized with the rubber component include styrene, α-methylstyrene, p-methylstyrene, alkoxystyrene, and halogenated styrene, with styrene being particularly preferred. Examples of acrylic esters include methyl acrylate, ethyl acrylate, butyl acrylate, cyclohexyl acrylate, and octyl acrylate. Examples of methacrylic esters include methyl methacrylate, ethyl methacrylate, butyl methacrylate, cyclohexyl methacrylate, and octyl methacrylate, with methyl methacrylate being particularly preferred. Among these, it is preferable to include methacrylic esters such as methyl methacrylate as an essential component. More specifically, the methacrylic ester is preferably contained in an amount of 10% by weight or more, more preferably 15% by weight or more, based on 100% by weight of the graft component (or 100% by weight of the shell in the case of a core-shell polymer).

[0113] Elastic polymers containing a rubber component with a glass transition temperature of 10°C or lower may be produced by any of the following polymerization methods: bulk polymerization, solution polymerization, suspension polymerization, and emulsion polymerization. The copolymerization method may be either single-stage or multi-stage grafting. They may also be a mixture with a copolymer of only the graft component, a by-product of production. Polymerization methods include conventional emulsion polymerization, soap-free polymerization using an initiator such as potassium persulfate, seed polymerization, and two-stage swelling polymerization. In suspension polymerization, the aqueous phase and the monomer phase are kept separate and precisely fed into a continuous disperser, with the particle size controlled by the rotation speed of the disperser. In continuous production, the particle size can be controlled by feeding the monomer phase into an aqueous liquid with dispersibility through a small orifice or porous filter with a diameter of several to several tens of micrometers. In the case of core-shell graft polymers, the reaction may be single-stage or multi-stage for both the core and shell.

[0114] Such elastic polymers are commercially available and easily available. For example, examples of those containing butadiene rubber, acrylic rubber, or butadiene-acrylic composite rubber as the main rubber component include Kane Ace B series (e.g., B-56) from Kanegafuchi Chemical Industry Co., Ltd., Metablen C series (e.g., C-223A) and W series (e.g., W-450A) from Mitsubishi Rayon Co., Ltd., Paraloid EXL series (e.g., EXL-2602), HIA series (e.g., HIA-15), BTA series (e.g., BTA-III), and KCA series from Kureha Chemical Industry Co., Ltd., Paraloid EXL series and KM series (e.g., KM-336P, KM-357P) from Rohm and Haas, and UCL Modifier Resin series from Ube Cycon Co., Ltd. (UMG ABS Co., Ltd.). AXS Resin series), and products with an acrylic-silicone composite rubber as the main rubber component include those sold by Mitsubishi Rayon Co., Ltd. under the trade names Metablen S-2001 or SRK-200.

[0115] The composition ratio of the impact improver is preferably 0.2 to 50 parts by weight, more preferably 1 to 30 parts by weight, and more preferably 1.5 to 20 parts by weight, per 100 parts by weight of the total of the polycarbonate resin and the acrylic resin. This composition range can impart good impact resistance to the composition while suppressing a decrease in rigidity.

[0116] [Heat deflection temperature: HDT] The resin composition of the present invention preferably has a deflection temperature under load (1.8 MPa) as specified by ISO 75 of 85°C or higher, more preferably 90°C or higher. Within this range, molded articles made from the resin composition will be less susceptible to thermal deformation in actual environments, making the composition particularly useful for applications such as electrical and electronic components, automotive components, seats, bottles, containers, and building materials. There is no particular upper limit to the deflection temperature under load, but a temperature of 150°C or lower is preferred.

[0117] [Pencil hardness] The resin composition of the present invention preferably has a pencil hardness of H or higher, more preferably 2H or higher. A pencil hardness of 4H or lower provides sufficient functionality. The pencil hardness can be increased by increasing the weight ratio of the acrylic resin. In the present invention, pencil hardness refers to the hardness at which no scratches remain when a molded article formed from the resin composition of the present invention is scratched with a pencil having a specific pencil hardness. The pencil hardness used in the surface hardness test of a coating film, which can be measured according to JIS K-5600, can be used as an index. Pencil hardness decreases in the following order: 9H, 8H, 7H, 6H, 5H, 4H, 3H, 2H, H, F, HB, B, 2B, 3B, 4B, 5B, and 6B, with the hardest being 9H and the softest being 6B.

[0118] [Transparency] The haze of a 2 mm thick molded article of the resin composition of the present invention is preferably 10% or less, more preferably 5% or less, even more preferably 3% or less, particularly preferably 2% or less, and most preferably 1% or less. A haze within the above range is preferable because the range of use as various transparent members is not limited.

[0119] [Impact strength] The resin composition of the present invention has a notched Charpy impact strength of 1.5 kJ / m as measured in accordance with ISO 179. 2 It is preferable that the concentration is 2 kJ / m or more. 2 More preferably, it is 3 kJ / m or more. 2 It is more preferable that the notched Charpy impact strength is 100 kJ / m or more. 2 The following functions are sufficient:

[0120] [Dynamic friction coefficient] The resin composition of the present invention has a dynamic friction coefficient of 0.05 to 0.30, preferably 0.06 to 0.27, and more preferably 0.07 to 0.25, as measured by the friction coefficient measurement test described below. A value within the above range is preferred because it can reduce the stress applied to the resin surface during the abrasion resistance test. Measurement method: Under an environment of 23°C and 50% RH, the coefficient of dynamic friction between the resin plate surface and the sapphire needle is measured using a surface property measuring instrument manufactured by Shinto Scientific (HEIDON). The sapphire needle has a tip shape of R0.7Φ, and the average value of three measurements taken under the condition of a load of 100g is used as the measured value.

[0121] [Molded products] The resin composition of the present invention can be molded and processed by any method, such as injection molding, compression molding, injection-compression molding, melt-casting, or casting, to form molded articles in the form of films, sheets, or various other shapes. Specific applications include molded articles such as automobile interior and exterior parts, optical lenses, optical disks, optical films, plastic substrates, optical cards, liquid crystal panels, headlamp lenses, light guide plates, diffusers, protective films, OPC binders, front panels, housings, trays, water tanks, light covers, signs, and plastic windows. In particular, the composition can be used for components requiring high surface hardness, such as front panels, housings, trays, water tanks, light covers, signs, and plastic windows.

[0122] [Surface treatment] Molded articles formed from the resin composition of the present invention can be subjected to various surface treatments. Surface treatments referred to here are those that form a new layer on the surface of a resin molded article, such as vapor deposition (physical vapor deposition, chemical vapor deposition, etc.), plating (electroplating, electroless plating, hot-dip plating, etc.), painting, coating, and printing, and commonly used methods can be applied. Specific examples of surface treatments include hard coating, water-repellent and oil-repellent coating, ultraviolet-absorbing coating, infrared-absorbing coating, and metallizing (vapor deposition, etc.). Hard coating is often required and is a particularly preferred surface treatment. [Example]

[0123] The present invention will be described in detail below with reference to examples, but the present invention is not limited thereto. In the examples, "parts" means "parts by weight." The resins used in the examples and the evaluation methods are as follows.

[0124] (Evaluation of polycarbonate resin) 1. Polymer composition ratio (NMR) Each repeating unit was measured by proton NMR using JNM-AL400 manufactured by JEOL Ltd., and the polymer composition ratio (molar ratio) was calculated.

[0125] 2. Specific viscosity The viscosity was measured using an Ostwald viscometer from a solution of 0.7 g of polycarbonate resin dissolved in 100 ml of methylene chloride at 20°C. Specific viscosity (η SP )=(t-t0) / t0 [t0 is the number of seconds that methylene chloride falls, and t is the number of seconds that the sample solution falls]

[0126] (Evaluation of Resin Composition) 3. Notched Charpy impact strength The notched Charpy impact test was performed according to ISO179. 4. Deflection temperature under load (1.8 MPa) The deflection temperature under load (HDT) under high load (1.8 MPa) specified in ISO75 was measured.

[0127] 5. Hayes Pellets of the polycarbonate resin composition were dried at 80-110°C for 12 hours, and then molded using an injection molding machine (Japan Steel Works, Ltd., JSW J-75EIII) at a molding temperature of 240-280°C, a mold temperature of 80°C, and a molding cycle of 50 seconds to produce a three-level plate with a width of 50 mm, a length of 90 mm, and thicknesses of 3.0 mm (20 mm length), 2.0 mm (45 mm length), and 1.0 mm (25 mm length) from the gate side, and an arithmetic mean roughness (Ra) of 0.03 μm. A 2 mm thick section of the molded three-level plate was measured using a Haze Meter 300A (Nippon Denshoku Industries Co., Ltd.).

[0128] 6.Pencil hardness Using the prepared three-tiered plate (2 mm thick section), a line was drawn on the surface of the composition in a thermostatic chamber at an ambient temperature of 23°C, in accordance with JIS K5400, with a pencil held at a 45° angle and a load of 750 g applied, and the surface condition was evaluated visually.

[0129] 7. Weather-resistant In accordance with JIS B7753, a Sunshine Weatherometer S80 manufactured by Suga Test Instruments Co., Ltd. was used. The discharge voltage was set to 50 V and the discharge current to 60 A using a Sunshine Carbon Arc (Ultra Long Life Carbon 4 pairs) light source. The square surface of an injection-molded specimen (60 mm wide x 60 mm long x 3 mm thick) was irradiated for 500 hours under conditions of a black panel temperature of 63°C and a relative humidity of 50%. The surface spray (rainfall) time was 12 minutes per hour. A type A glass filter was used. The color difference ΔE of the specimen before and after the test was measured using a spectrophotometer SE-2000 manufactured by Nippon Denshoku Industries Co., Ltd. The smaller the ΔE, the less discoloration there was. ΔE is preferably 3.0 or less, more preferably 2.5 or less, and even more preferably 2.0 or less. ΔE={(ΔL) 2 +(Δa) 2 +(Δb) 2} 1 / 2 ...Formula (a) Color of "molded plate before test": L, a, b Color of "molded plate after test": L', a', b' ΔL:L-L' Δa:a-a' Δb:b-b'

[0130] 8. Coefficient of kinetic friction The coefficient of dynamic friction between the surface of a three-stage plate (2 mm thick) and a sapphire stylus was measured using a surface property measuring instrument manufactured by Shinto Scientific (HEIDON) under an environment of 23°C and 50% RH. The sapphire stylus had a tip shape of R0.7Φ, and the average value of three measurements was taken under the condition of a load of 100 g.

[0131] 9. Abrasion resistance test 3M 261X polish paper was attached to an Imoto Manufacturing Co., Ltd. rubbing tester IMC-1507 model as abrasive paper, and a weight was attached so that a 2 mm thick portion of the three-stage plate was pressed against it, with a load of 9 N. The abrasion test was carried out five times, back and forth, at 23°C and 50% RH. A gloss meter, NIPPON DENSOKU HANDY GLOSS METER PG-1M, was used to measure the 20° gloss of the molded plate surface before and after the test, and the gloss change rate was calculated using the following formula. The smaller the gloss change rate, the better the abrasion resistance. A gloss change rate of 50% or less is preferred. Gloss change rate (%) = (20° glossiness before test - 20° glossiness after test) / (20° glossiness before test) x 100

[0132] [Polycarbonate resin] PC1 (Example): Structural units derived from isosorbide (hereinafter referred to as ISS) / structural units derived from 3,9-bis(2-hydroxy-1,1-dimethylethyl)-2,4,8,10-tetraoxaspiro(5,5)undecane (hereinafter referred to as SPG) / structural units derived from 1,9-nonanediol (hereinafter referred to as ND) = 75 / 20 / 5 (mol %), specific viscosity 0.396 PC2 (Example): Structural units derived from ISS / structural units derived from SPG = 50 / 50 (mol%), specific viscosity 0.385 PC3 (comparison example): Teijin Limited Panlite L-1225 (100 mol% structural units derived from bisphenol A) PC4 (comparison example): Structural units derived from ISS / structural units derived from 1,4-cyclohexanedimethanol (hereinafter referred to as CHDM) = 70 / 30, specific viscosity 0.378

[0133] [Acrylic resin] PMMA1 (Example) Mitsubishi Rayon's ACRYPET VH-001 (acrylic resin copolymerized with 95 mol% methyl methacrylate and 5 mol% methyl acrylate)

[0134] [Sliding modifier] C1 (Example): Bisamide LA (methylene bisstearamide; hereafter abbreviated as Bis-LA) manufactured by Mitsubishi Chemical Corporation C2 (Example): Amide AP-1 (stearic acid amide; hereinafter abbreviated as AP-1) manufactured by Mitsubishi Chemical Corporation

[0135] [Example 1] <Production of polycarbonate resin> 354 parts of isosorbide (hereinafter abbreviated as ISS), 263 parts of 3,9-bis(2-hydroxy-1,1-dimethylethyl)-2,4,8,10-tetraoxaspiro(5,5)undecane (hereinafter abbreviated as SPG), 28 parts of 1,9-nonanediol (hereinafter abbreviated as ND), 750 parts of diphenyl carbonate (hereinafter abbreviated as DPC), and 0.8 x 10 parts of tetramethylammonium hydroxide and 0.6 x 10 parts of barium stearate as catalysts were heated to 200 °C under a nitrogen atmosphere and melted. The temperature was then raised to 220 °C over 30 minutes and the vacuum was adjusted to 20.0 kPa. The temperature was then raised to 240 °C over another 30 minutes and the vacuum was adjusted to 10 kPa. After maintaining this temperature for 10 minutes, the vacuum was reduced to 133 Pa or less over 1 hour. After the reaction was completed, the reaction mixture was discharged from the bottom of the reaction vessel under nitrogen pressure, and while being cooled in a water bath, it was cut with a pelletizer to obtain pellets (PC1).

[0136] <Production of Resin Composition> Polycarbonate resin PC1 and acrylic resin PMMA1 were used. Each resin was dried at 80°C for 12 hours or more, then mixed at a weight ratio of 70:30. One part by weight of sliding modifier C1 was added per 100 parts by weight of the total resin. The mixture was then melt-kneaded at 240°C in both the cylinder and die of a vented twin-screw extruder (Technovel Corporation, KZW15-25MG) to obtain resin composition pellets. A portion of the resulting pellets was dried at 90°C for 12 hours or more, and then molded into test specimens for various evaluations using an injection molding machine. The evaluation results are shown in Table 1.

[0137] [Example 2] <Production of Resin Composition> Except for adding 3 parts by weight of sliding modifier C1 to 100 parts by weight of the resin, the same procedures as in Example 1 were carried out and the same evaluations were carried out. The results are shown in Table 1.

[0138] [Example 3] <Production of Resin Composition> The blend weight ratio was PC1:PMMA1 = 50 / 50 (weight ratio), and 2 parts by weight of sliding modifier C1 was added per 100 parts by weight of the total resin, but the same procedures and evaluations were carried out as in Example 1. The results are shown in Table 1.

[0139] [Example 4] <Production of Resin Composition> The blend weight ratio was PC1:PMMA1=90 / 10 (weight ratio), and 2 parts by weight of sliding modifier C1 was added per 100 parts by weight of the total resin, but the same procedures and evaluations were carried out as in Example 1. The results are shown in Table 1.

[0140] [Example 5] <Production of Resin Composition> Except for adding 1 part by weight of sliding modifier C2 to 100 parts by weight of the total resin, the same procedures as in Example 1 were carried out and the same evaluations were carried out. The results are shown in Table 1.

[0141] [Example 6] <Production of Resin Composition> Except for adding 3 parts by weight of sliding modifier C2 to 100 parts by weight of the total resin, the same procedures as in Example 1 were carried out and the same evaluations were carried out. The results are shown in Table 1.

[0142] [Example 7] <Production of polycarbonate resin> 253 parts of ISS, 527 parts of SPG, 750 parts of DPC, and 0.8 x 10 parts of tetramethylammonium hydroxide and 0.6 x 10 parts of barium stearate as catalysts were heated to 200°C under a nitrogen atmosphere and melted. The temperature was then increased to 220°C over 30 minutes, and the vacuum was adjusted to 20.0 kPa. The temperature was then increased to 240°C over another 30 minutes, and the vacuum was adjusted to 10 kPa. After maintaining this temperature for 10 minutes, the vacuum was reduced to 133 Pa or less over 1 hour. After the reaction was completed, the mixture was discharged from the bottom of the reaction vessel under nitrogen pressure, cooled in a water bath, and cut into pellets using a pelletizer (PC2).

[0143] <Production of Resin Composition> Polycarbonate resin PC2 and acrylic resin PMMA1 were used. Each resin was dried at 90°C for 12 hours or more, then mixed at a weight ratio of 70:30. Two parts by weight of sliding modifier C1 was added per 100 parts by weight of the total resin. The mixture was then melt-kneaded at 250°C in both the cylinder and die of a vented twin-screw extruder (Technovel Corporation, KZW15-25MG) to obtain resin composition pellets. A portion of the resulting pellets was dried at 90°C for 12 hours or more, and then molded into test specimens for various evaluations using an injection molding machine. The evaluation results are shown in Table 1.

[0144] [Comparative Example 1] <Production of Resin Composition> Except for not adding sliding modifier C1, the same procedures as in Example 1 were carried out and the same evaluations were carried out. The results are shown in Table 1. The dynamic friction coefficient was high, and the gloss retention rate in the wear resistance test was inferior to that of Example 1.

[0145] Comparative Example 2 <Production of Resin Composition> The evaluation was carried out in exactly the same manner as in Example 1, except that only Panlite L-1225 (PC3) manufactured by Teijin Limited was used and the extrusion temperature and molding temperature were set to 280°C. The results are shown in Table 1. The surface hardness, weather resistance, and abrasion resistance were inferior to those of the Examples.

[0146] Comparative Example 3 <Production of Resin Composition> The evaluation was carried out in exactly the same manner as in Example 1, except that only the acrylic resin PMMA1 was used and the extrusion temperature and molding temperature were set to 250°C. The results are shown in Table 1. The impact resistance, deflection temperature under load, and abrasion resistance were inferior to those of the Examples.

[0147] Comparative Example 4 <Production of polycarbonate resin> Pellets (PC4) were obtained in the same manner as in Example 7, except that 354 parts of ISS, 150 parts of CHDM, and 750 parts of DPC were used as raw materials. <Production of Resin Composition> The same evaluation as in Example 7 was carried out except that 2 parts by weight of the sliding modifier C1 was added to 100 parts by weight of the polycarbonate resin (PC4). The results are shown in Table 1. The surface hardness and abrasion resistance were inferior to those of the Examples.

[0148] Comparative Example 5 <Production of Resin Composition> The blend weight ratio was PC4:PMMA1=70 / 30 (weight ratio), and extrusion was performed, but whitened pellets were obtained. The molded product was also whitened, and transparency was not maintained at all.

[0149] [Table 1] [Industrial Applicability]

[0150] The resin composition of the present invention is excellent in transparency, heat resistance, impact resistance, weather resistance, surface hardness, and abrasion resistance, and is therefore useful as components for automobile interior and exterior parts, optical lenses, optical disks, optical films, plastic cell substrates, optical cards, liquid crystal panels, headlamp lenses, light guide plates, diffusion plates, protective films, OPC binders, front panels, housings, trays, aquariums, lighting covers, signs, plastic windows, and the like.

Claims

1. A resin composition comprising (A) a polycarbonate resin, (B) an acrylic resin, and (C) a sliding modifier, the resin composition having a dynamic friction coefficient of 0.05 to 0.30, (A) The polycarbonate resin contains 5 to 85 mol % of repeating units (a-1) represented by the following formula (1) based on all repeating units: 【Chemistry 1】 (In the formula, W represents an alkylene group having 1 to 20 carbon atoms or a cycloalkylene group having 6 to 20 carbon atoms, R 1 represents a branched or linear alkyl group having 1 to 20 carbon atoms or a cycloalkyl group having 6 to 20 carbon atoms which may have a substituent, and m represents an integer of 0 to 10.) (B) The acrylic resin contains 10 to 100 mol % of a repeating unit (b) represented by the following formula (3): 【Chemistry 2】 (In the formula, R 2 represents a hydrogen atom or a methyl group, and R 3 represents a branched or linear alkyl group having 1 to 20 carbon atoms or a cycloalkyl group having 6 to 20 carbon atoms which may have a substituent.) (C) A resin composition in which the sliding modifier is a fatty acid amide-based sliding modifier.

2. The resin composition according to claim 1, wherein the polycarbonate resin (A) contains 15 to 95 mol % of the repeating unit (a-2) represented by the following formula (2) based on all repeating units: 【Transformation 3】

3. 3. The resin composition according to claim 1, wherein the repeating unit (b) is a unit (b) derived from methyl methacrylate and / or methyl acrylate.

4. 4. The resin composition according to claim 1, wherein the weight ratio of the polycarbonate resin (A) to the acrylic resin (B) is 1:99 to 99:

1.

5. 5. The resin composition according to claim 1, wherein the content of the sliding modifier (C) is 0.1 to 20 parts by weight per 100 parts by weight of the total of the polycarbonate resin and the acrylic resin.

6. 6. The resin composition according to claim 1, which has a pencil hardness of H or more as measured in accordance with JIS K5400.

7. 7. The resin composition according to claim 1, wherein a molded article having a thickness of 2 mm obtained by molding the resin composition has a haze of 10% or less.

8. A molded article obtained by molding the resin composition according to any one of claims 1 to 7.

9. A film or sheet formed from the resin composition according to any one of claims 1 to 7.

Images